U.S. patent application number 14/259761 was filed with the patent office on 2014-10-23 for magnetic component and transformer made therefrom.
This patent application is currently assigned to Enphase Energy, Inc.. The applicant listed for this patent is Enphase Energy, Inc.. Invention is credited to Michael Harrison.
Application Number | 20140313004 14/259761 |
Document ID | / |
Family ID | 51728572 |
Filed Date | 2014-10-23 |
United States Patent
Application |
20140313004 |
Kind Code |
A1 |
Harrison; Michael |
October 23, 2014 |
MAGNETIC COMPONENT AND TRANSFORMER MADE THEREFROM
Abstract
A magnetic component and transformer made therefrom is provided.
The magnetic component includes an outer circular wall including a
first gap and a second gap; an inner circular wall including a
third gap and a fourth gap; and a cylindrical core. The outer
circular wall, the inner circular wall, and the cylindrical core
are concentric to one another. The outer circular wall and the
inner circular wall are spaced apart to define an outer radial
channel. The inner circular wall and the cylindrical core are
spaced apart to define an inner radial channel. A transformer is
formed by wrapping a first winding about the inner circular wall
and a second winding around the cylindrical core.
Inventors: |
Harrison; Michael;
(Petaluma, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Enphase Energy, Inc. |
Petaluma |
CA |
US |
|
|
Assignee: |
Enphase Energy, Inc.
Petaluma
CA
|
Family ID: |
51728572 |
Appl. No.: |
14/259761 |
Filed: |
April 23, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61815096 |
Apr 23, 2013 |
|
|
|
61920100 |
Dec 23, 2013 |
|
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Current U.S.
Class: |
336/178 |
Current CPC
Class: |
H01F 3/10 20130101; H01F
27/306 20130101; H01F 3/12 20130101; H01F 27/2828 20130101 |
Class at
Publication: |
336/178 |
International
Class: |
H01F 27/24 20060101
H01F027/24 |
Claims
1. A magnetic component, comprising: an outer circular wall
including a first gap and a second gap; an inner circular wall
including a third gap and a fourth gap; and a cylindrical core,
wherein the outer circular wall, the inner circular wall, and the
cylindrical core are concentric to one another, wherein the outer
circular wall and the inner circular wall are spaced apart to
define an outer radial channel; wherein the inner circular wall and
the cylindrical core are spaced apart to define an inner radial
channel.
2. The magnetic component of claim 1, further comprising: a first
portion including a first outer circular wall, a first inner
circular wall, and a first cylindrical core; and a second portion
including a second outer circular wall, a second inner circular
wall, and a second cylindrical core, wherein a first face of the
first portion and a second face of the second portion are coupled
to each other.
3. The magnetic component of claim 2, further comprising an air gap
between the first inner circular wall and the second inner circular
wall, wherein the first outer circular wall sits flush against the
second outer circular wall, and wherein the first cylindrical core
sits flush against the second cylindrical core.
4. The magnetic component of claim 1, further comprising: a sensor
post disposed in one of the third gap or the fourth gap.
5. The magnetic component of claim 1, wherein the first gap is
offset from the second gap by 90 degrees around a center of the
cylindrical core.
6. The magnetic component of claim 1, wherein the first gap and the
second gap are disposed on opposite sides of the magnetic
component.
7. A transformer, comprising: an outer circular wall including a
first gap and a second gap; an inner circular wall including a
third gap and a fourth gap; a cylindrical core; a first coil
winding wrapped around the cylindrical core; and a second coil
winding wrapped around the inner circular wall, wherein the outer
circular wall, the inner circular wall, and the cylindrical core
are concentric to one another, wherein the outer circular wall and
the inner circular wall are spaced apart to define an outer radial
channel; wherein the inner circular wall and the cylindrical core
are spaced apart to define an inner radial channel.
8. The transformer of claim 7, further comprising: a first portion
including a first outer circular wall, a first inner circular wall,
and a first cylindrical core; and a second portion including a
second outer circular wall, a second inner circular wall, and a
second cylindrical core, wherein a first face of the first portion
and a second face of the second portion are coupled to each other
such that the first outer circular wall sits flush against the
second outer circular wall, the first cylindrical core sits flush
against the second cylindrical core, and the first inner circular
wall is separated from the second inner circular wall by an air
gap.
9. The transformer of claim 8, wherein the first coil winding is
wrapped around a first winding bobbin that surrounds the
cylindrical core and the second coil winding is wrapped around a
second winding bobbin that surrounds the inner circular wall.
10. The transformer of claim 9, wherein the first outer circular
wall and the first inner circular wall define a first outer radial
channel and the second outer circular wall and the second inner
circular wall define a second outer radial channel, wherein the
first inner circular wall and the first cylindrical core define a
first inner radial channel and the second inner circular wall and
the second cylindrical core define a second inner radial channel,
and wherein the first outer radial channel and the second outer
radial channel form the outer radial channel of the transformer and
the first inner radial channel and the second inner radial channel
form the inner radial channel of the transformer when the first
portion is coupled to the second portion.
11. The transformer of claim 10, wherein the first winding bobbin
is seated in the first outer radial channel and extends into the
second outer radial channel when the first portion is coupled to
the second portion, and wherein the second winding bobbin is seated
in the second inner radial channel and extends into the first inner
radial channel.
12. The transformer of claim 11, wherein the first winding bobbin
partially extends into the second outer radial channel and the
second winding bobbin occupies an entirety of the inner radial
channel of the transformer.
13. The transformer of claim 7, wherein the first gap is offset
from the second gap by 90 degrees around a center of the
cylindrical core.
14. The transformer of claim 7, wherein the first gap and the
second gap are disposed on opposite sides of the transformer.
15. The transformer of claim 7, further comprising: a sensor post
disposed in one of the third gap or the fourth gap of the inner
circular wall; and a current sensor coil winding wrapped around the
sensor post.
16. The transformer of claim 15, wherein a thickness the current
sensor coil winding is less than respective thicknesses of the
first coil winding and the second coil winding.
17. An integrated magnetic component, comprising: a substrate; a
top magnetic component including a plurality of notches on a
backside of the top magnetic component; a base magnetic component
sized and shaped similarly to the top magnetic component, the base
magnetic component disposed on the substrate; and a plurality of
fastener clips to couple to the plurality of notches, the plurality
of fastener clips coupling the top magnetic component, the base
magnetic component, and the substrate together, the top magnetic
component, comprising: a first outer circular wall including a
first gap and a second gap; a first inner circular wall including a
third gap and a fourth gap; and a first cylindrical core, wherein
the first outer circular wall, the first inner circular wall, and
the first cylindrical core are concentric to one another, wherein
the first outer circular wall and the first inner circular wall are
spaced apart to define a first outer radial channel, and wherein
the first inner circular wall and the first cylindrical core are
spaced apart to define a first inner radial channel; and the base
magnetic component, comprising: a second outer circular wall
including a fifth gap and a sixth gap; a second inner circular wall
including a seventh gap and an eighth gap; and a second cylindrical
core, wherein the second outer circular wall, the second inner
circular wall, and the second cylindrical core are concentric to
one another, wherein the second outer circular wall and the second
inner circular wall are spaced apart to define a second outer
radial channel, and wherein the second inner circular wall and the
second cylindrical core are spaced apart to define a second inner
radial channel, wherein the top magnetic component and the base
magnetic component are physically and magnetically coupled to one
another to form a transformer, wherein, when the top magnetic
component is coupled to the base magnetic component, the first
outer circular wall is aligned with the second outer circular wall,
the first inner circular wall is aligned with the second inner
circular wall, the first cylindrical core is aligned with the
second cylindrical core, the first outer radial channel is aligned
with the second outer radial channel, and the first inner radial
channel is aligned with the second inner radial channel, wherein,
when the top magnetic component is coupled to the base magnetic
component, the first outer circular wall lies flush against the
second outer circular wall and the first cylindrical core lies
flush against the second cylindrical core, wherein, when the top
magnetic component is coupled to the base magnetic component, the
first inner circular wall and the second inner circular wall are
spaced apart by an air gap, and wherein, when the top magnetic
component is coupled to the base magnetic component, the first gap
is aligned with the fifth gap, the second gap is aligned with the
sixth gap, the third gap is aligned with the seventh gap, and the
fourth gap is aligned with the eighth gap.
18. The integrated magnetic component of claim 17, further
comprising: a sensor post disposed in one of the third gap, the
fourth gap, the seventh gap, or the eighth gap.
19. The integrated magnetic component of claim 17, wherein the
first and fifth gaps are offset from the second and sixth gaps by
90 degrees around a center of the first and second cylindrical
cores.
20. The integrated magnetic component of claim 17, wherein the
first and fifth gaps are disposed opposite to the second and sixth
gaps.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/815,096 filed on Apr. 23, 2013 and U.S.
Provisional Patent Application No. 61/920,100 filed on Dec. 23,
2013, which are incorporated by reference herein in their
entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present disclosure relate generally to
transformers and, in particular, a highly integrated magnetic
component for a transformer.
[0004] 2. Description of the Related Art
[0005] Transformers are used in a variety of devices to perform
functions such as altering a voltage level, circuit isolation,
measuring voltage or current in electrical power systems, and a
host of other functions. In order to provide sufficient space for
the windings, the winding area of a transformer is generally large
as compared to a cross-sectional area of the transformer's core,
resulting in a large form-factor. In some instances, the
transformer occupies valuable usable space because of the large
form factor.
[0006] Therefore, there is a need in the art for a space efficient,
compact transformer having magnetic components that are small and
compact.
SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention generally relate to
transformers and a highly integrated magnetic component.
[0008] Various advantages, aspects and novel features of the
present disclosure, as well as details of an illustrated embodiment
thereof, will be more fully understood from the following
description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] So that the manner in which the above recited features of
the present invention can be understood in detail, a more
particular description of the invention, briefly summarized above,
may be had by reference to embodiments, some of which are
illustrated in the appended drawings. It is to be noted, however,
that the appended drawings illustrate only typical embodiments of
this invention and are therefore not to be considered limiting of
its scope, for the invention may admit to other equally effective
embodiments.
[0010] FIG. 1 is an isometric view of a transformer formed by
stacking two integrated magnetic portions in accordance with an
embodiment of the present invention;
[0011] FIG. 2 is a side view formed by stacking a first integrated
magnetic portion and a second integrated magnetic portion to form a
transformer in accordance with an embodiment of the present
invention;
[0012] FIG. 3 is an illustration from a cross-sectional view of the
transformer of FIG. 2 in accordance with an embodiment of the
present invention;
[0013] FIG. 4 is an isometric illustration of a first integrated
magnetic portion and a second integrated magnetic portion of the
integrated magnetic component in accordance with an embodiment of
the present invention;
[0014] FIG. 5 is an isometric illustration of a portion of an
integrated magnetic component in accordance with an embodiment of
the present invention;
[0015] FIG. 6 is an illustration from a top view of the portion of
the integrated magnetic component in FIG. 5 in accordance with an
embodiment of the present invention;
[0016] FIG. 7 is an isometric illustration from a back view of the
portion of the integrated magnetic component in FIG. 5 in
accordance with an embodiment of the present invention; and
[0017] FIG. 8 is an illustration from a top view of a portion of
the integrated magnetic component in accordance with an alternative
embodiment of the present invention.
DETAILED DESCRIPTION
[0018] Embodiments of the present invention comprise a magnetic
component having a unitary magnetic body comprising concentric
radial channels. The channels define cores for primary and
secondary windings. As will be discussed herein, the channels and
respective windings form a compact, space efficient
transformer.
[0019] FIG. 1 is an isometric view of a transformer 100 formed by
stacking two integrated magnetic portions in accordance with an
embodiment of the present invention. The transformer 100 is mounted
to a substrate 102.
[0020] The transformer 100 comprises a first integrated magnetic
portion 106 (i.e., a top magnetic component, hereinafter referred
to as first portion 106) and respective windings coupled to a
second integrated magnetic portion 108 (i.e., a base magnetic
component, hereinafter referred to as second portion 108) and
respective windings. A first winding (i.e., a primary coil winding)
and a second winding (i.e., a secondary coil winding) exit
respective gaps 110 and 112 and are coupled to external circuitry
(not shown). A plurality of fastener clips 104 are coupled to a
plurality of fastener notches 120 on a backside of the first
portion 106. The plurality of fastener clips 104 couple the faces
of the first and second portions 106 and 108 together and, in some
embodiments, couples to a corresponding fastener notch located on
an underside of the second portion 108. In some embodiments, the
plurality of fastener clips 104 may instead be coupled to the
substrate 102 or other securing base.
[0021] FIG. 2 shows a side view of the transformer 100 in
accordance with an embodiment of the present invention. FIG. 3
shows a cross section of the transformer 100 shown in FIG. 2 taken
along the line 3-3.
[0022] As illustrated in FIGS. 2 and 3, the transformer 100 is
formed by coupling the face of the first portion 106 to the face of
the second portion 108. The first portion 106 is coupled to the
second portion 108 such that an outer circular wall 302 and a
cylindrical core 306 of the first portion 106 are in contact with a
second outer circular wall 322 and a second cylindrical core 326 of
the second portion 108, respectively. An inner circular wall 304 of
the first portion 106 and a second inner circular wall 324 of the
second portion 108 face one another but are separated by an air gap
350. A first winding bobbin 312 is seated in an outer radial
channel 308 of the first portion 106 and extends into a second
outer radial channel 328 of the second portion 108. A first coil
winding 202 is wrapped around the first winding bobbin 312. A
second winding bobbin 332 is seated in a second inner radial
channel 330 of the second portion 108 and extends into an inner
radial channel 310 of the first portion 106. A second coil winding
204 is wrapped around the second winding bobbin 332. In some
embodiments, the second winding bobbin 332 occupies the entirety of
the inner radial channel 310 and the second inner radial channel
330 while the first winding bobbin 312 partially extends into the
second outer radial channel 328 to allow the second coil winding
204 to pass beneath it and exit the transformer 100, as illustrated
in FIG. 3. Although the first portion 106 and the second portion
108 are illustrated as the top and bottom portions, respectively,
it should be noted that this orientation may be reversed.
Similarly, the first coil winding 202 may be either of the primary
or secondary coil winding and the second coil winding 204 may be
the other of the primary or secondary coil winding.
[0023] In some embodiments, the first coil winding 202 may comprise
a copper trace on a substrate (e.g., polyamide, fiberglass, FR4,
etc.) and the second coil winding 204 may comprise copper wire and
may be insulated (e.g., such as Litz wire). In some embodiments,
the first coil winding 202 may be a single loop and the second coil
winding 204 may be a plurality (e.g., 8) of loops. However, it
should be noted that the first and second coil windings 202, 204
may be formed of any conductive material and may include any number
of loops sufficient to perform the functionality of the present
invention. The bobbins 312, 332 are typically cylindrical and may
include upper and lower flanges. The diameter of the bobbins 312,
332 are substantially are substantially equal to the diameters of
their respective channels and in some embodiments comprise a
plastic or other non-conductive material. The bobbins 312, 332 are
press fit around their respective cores to ensure that they remain
in place. Alternatively, in some embodiments, an adhesive may be
used to ensure that the bobbins 312, 332 remain in place. In the
embodiments in which the second winding bobbin 332 occupies the
entirety of the inner radial channel 310 and the second inner
radial channel 330 and the first winding bobbin 312 partially
extends into the second outer radial channel 328, the secondary
winding bobbin 332 is held in place by both portions 106, 108 and
the first winding bobbin 312 is held in place by the second coil
winding 204 that passes beneath first winding bobbin 312 to exit
the transformer 100. The first portion 106 and second portion 108
may be formed of ferrite, manganese zinc ceramic, and the like. A
cross section of the cores, walls, and channels, are substantially
square or rectangular, however alternative embodiments may be
rounded.
[0024] FIG. 4 is an isometric illustration of the first portion 106
and the second portion 108 of the integrated magnetic component in
accordance with an embodiment of the present invention. The first
portion 106 includes the first coil winding 202 wound around the
first winding bobbin 312. The first winding bobbin 312 is seated
into the outer radial channel 308. The first winding bobbin 312 is
thus located between the outer circular wall 302 and the inner
circular wall 304. The ends of the first coil winding 202 are
seated and pass through a first gap 402 in the outer circular wall
302.
[0025] The second portion 108 includes a substantially symmetrical
structure to that of the first portion 106. The second portion 108
includes the second outer circular wall 322, the second inner
circular wall 324, and the second cylindrical core 326. The second
portion 108 further comprises the second coil winding 204 wound
around the second winding bobbin 332. The second winding bobbin 332
is seated in the second inner radial channel 330 located between
the second inner circular wall 324 and the second cylindrical core
326. The second outer radial channel 328 is located between the
second outer circular wall 322 and the second inner circular wall
324. The ends of the second coil winding 204 pass through a second
gap 404 in the second inner circular wall 324 and exit the second
portion 108 via a third gap 406 in the second outer circular wall
322.
[0026] The following description will be made in reference to FIGS.
5 and 6. FIG. 5 is an isometric illustration of a portion 500 of an
integrated magnetic component in accordance with an embodiment of
the present invention. FIG. 6 is an illustration from a top view of
the portion 500 of the integrated magnetic component in FIG. 5. In
some embodiments, the portion 500 is substantially circular.
However, it should be noted that the portion 500 may have any shape
capable of performing the functions disclosed herein. The portion
500 includes an outer wall 502, an inner wall 504 disposed within
the outer wall 502, and a cylindrical core 506 disposed within the
inner wall 504, all of which extend from a base 520. In some
embodiments, the outer wall 502, the inner wall 504, and the
cylindrical core 506 are concentric to one another.
[0027] The outer wall 502 may include a first gap 508 and a second
gap 510. The inner wall 504 may include a third gap 512 and a
fourth gap 514 which are aligned with the first and second gaps
508, 510, respectively. The first gap 508 and the second gap 510
are offset by 90 degrees around the center of the cylindrical core
506. In alternative embodiments, the first gap 508 and second gap
510 are offset by a different angle or located on opposite sides of
the portion 500 (e.g., FIG. 4). Although the outer wall 502 is
illustrated with two gaps 508, 510, it should be noted that the
outer wall 502 may include any number of gaps (i.e., one or more)
that allows cables within the integrated magnetic component to
couple to external circuitry. The first and second gaps 508, 510
couple to an outer radial channel 516 defined between the outer
wall 502 and the inner wall 504. The first and second gaps 508, 510
also couple to an inner radial channel 518 defined between the
inner wall 504 and the cylindrical core 506 via the third and
fourth gaps 512, 514.
[0028] The outer walls 502 and cylindrical core 506 may be of
substantially the same height so when the portion 500 is stacked
onto a second portion, the assembly forms a substantially flush
contact between corresponding outer walls and cores to house
cabling (not shown). The inner wall 504 may be shorter than the
outer wall 502 and the cylindrical core 506 so when the portion 500
is stacked onto the second portion, the assembly forms an air gap
between the corresponding inner walls, as previously explained. In
some embodiments, the walls may be annular, circular, or comprise a
shape with rounded edges.
[0029] In some embodiments, a first cabling may be looped around
the cylindrical core 506 through the first and third gaps 508 and
512 and a second cabling may be looped around the inner wall 504
(of another portion) through the second gap 510. During assembly,
each respective cabling may be looped on opposite facing portions
before stacking. Alternatively, cabling may be wrapped around a
bobbin (not shown) before stacking. In another embodiment, a first
and second cabling may be wrapped around the corresponding
cylindrical cores of the respective top and base portions and
respectively extend through gap pairs 508/512 and 510/514. The
cabling may be a braided cable or twisted wire.
[0030] FIG. 7 is an isometric illustration from a back view of the
portion 500 of the integrated magnetic component in FIG. 5 in
accordance with an embodiment of the present invention. The base
520 may include fastener notches 602 which are used to couple two
portions together to form a transformer, as shown in FIG. 1 and
described above.
[0031] FIG. 8 is an illustration from a top view of an integrated
magnetic portion 800 in accordance with an alternative embodiment
of the present invention. The portion 800 is substantially similar
to the portion 500 of FIG. 5 and includes an outer wall 802, an
inner wall 804, and a cylindrical core 806. However, the portion
800 additionally includes a sensor post 850 that replaces one of
the inner gaps formed in the inner wall 804. A description of
elements of the portion 800 that are similar to those of the
portion 500 will be omitted here for the sake of conciseness. The
sensor post 850 is of substantially the same height as the outer
wall 802 and the cylindrical core 806 so that when the portion 800
is stacked onto another portion, the sensor posts, outer walls, and
cylindrical cores of the two portions are in substantially flush
contact.
[0032] The sensor post 850 forms a core around which a current
sensor coil winding (not shown) is wrapped. The wrapping of the
current sensor coil winding may be similar to that of the winding
of the first and second coil windings 202, 204 described above with
respect to FIG. 3. That is, the current sensor coil winding may be
wound around a current sensor bobbin, which is seated around the
sensor post 850. The ends of the current sensor coil winding pass
through the nearest gap in the outer wall 802. The current sensor
coil winding may be of a thinner gauge than that of the first and
second coil windings 202, 204. With the thinner gauge coil, the
current sensor coil winding may exit the portion 800 using the same
gap as the first or second coil winding without electrically or
mechanically interfering with the first or second coil winding.
Sensor circuitry (not shown) is coupled to the sensor coil winding
and the sensor circuitry measures the current of the primary
winding (i.e., the current sensor winding yields a measurable
current that is indicative of the primary current on the winding of
the primary coil winding).
[0033] The foregoing description of embodiments of the invention
comprises a number of elements, devices, circuits and/or assemblies
that perform various functions as described. These elements,
devices, circuits, and/or assemblies are exemplary implementations
of means for performing their respectively described functions.
[0034] While the foregoing is directed to embodiments of the
present invention, other and further embodiments of the invention
may be devised without departing from the basic scope thereof.
* * * * *